US9233363B2 - Catalyst preparation reactors from catalyst precursor used for feeding reactors to upgrade heavy hydrocarbonaceous feedstocks - Google Patents

Catalyst preparation reactors from catalyst precursor used for feeding reactors to upgrade heavy hydrocarbonaceous feedstocks Download PDF

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US9233363B2
US9233363B2 US13/808,469 US201113808469A US9233363B2 US 9233363 B2 US9233363 B2 US 9233363B2 US 201113808469 A US201113808469 A US 201113808469A US 9233363 B2 US9233363 B2 US 9233363B2
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catalyst
process according
dedicated
hydroconversion
reactor
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US20130193035A1 (en
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Didier Borremans
Maxime Lacroix
Katell Le Lannic-Dromard
gloria Vendrell
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TotalEnergies Raffinage France SAS
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Total Marketing Services SA
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    • B01J31/00—Catalysts comprising hydrides, coordination complexes or organic compounds
    • B01J31/16—Catalysts comprising hydrides, coordination complexes or organic compounds containing coordination complexes
    • B01J31/22—Organic complexes
    • B01J31/2282—Unsaturated compounds used as ligands
    • B01J31/2295—Cyclic compounds, e.g. cyclopentadienyls
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    • B01J31/22—Organic complexes
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    • B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
    • B01J37/16—Reducing
    • B01J37/18—Reducing with gases containing free hydrogen
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01J37/20—Sulfiding
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    • C10G49/00—Treatment of hydrocarbon oils, in the presence of hydrogen or hydrogen-generating compounds, not provided for in a single one of groups C10G45/02, C10G45/32, C10G45/44, C10G45/58 or C10G47/00
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    • C10G65/00—Treatment of hydrocarbon oils by two or more hydrotreatment processes only
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    • C10G65/00—Treatment of hydrocarbon oils by two or more hydrotreatment processes only
    • C10G65/02—Treatment of hydrocarbon oils by two or more hydrotreatment processes only plural serial stages only
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    • C10G65/00—Treatment of hydrocarbon oils by two or more hydrotreatment processes only
    • C10G65/02—Treatment of hydrocarbon oils by two or more hydrotreatment processes only plural serial stages only
    • C10G65/12—Treatment of hydrocarbon oils by two or more hydrotreatment processes only plural serial stages only including cracking steps and other hydrotreatment steps
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    • B01J2231/60—Reduction reactions, e.g. hydrogenation
    • B01J2231/64—Reductions in general of organic substrates, e.g. hydride reductions or hydrogenations
    • B01J2231/641—Hydrogenation of organic substrates, i.e. H2 or H-transfer hydrogenations, e.g. Fischer-Tropsch processes
    • B01J2231/645—Hydrogenation of organic substrates, i.e. H2 or H-transfer hydrogenations, e.g. Fischer-Tropsch processes of C=C or C-C triple bonds
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    • B01J2231/60—Reduction reactions, e.g. hydrogenation
    • B01J2231/64—Reductions in general of organic substrates, e.g. hydride reductions or hydrogenations
    • B01J2231/641—Hydrogenation of organic substrates, i.e. H2 or H-transfer hydrogenations, e.g. Fischer-Tropsch processes
    • B01J2231/646—Hydrogenation of organic substrates, i.e. H2 or H-transfer hydrogenations, e.g. Fischer-Tropsch processes of aromatic or heteroaromatic rings
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    • B01J23/16—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
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    • B01J23/76—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
    • B01J23/84—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36 with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
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    • B01J2531/50—Complexes comprising metals of Group V (VA or VB) as the central metal
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    • B01J35/20—Catalysts, in general, characterised by their form or physical properties characterised by their non-solid state
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    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
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    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
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    • C—CHEMISTRY; METALLURGY
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P30/00—Technologies relating to oil refining and petrochemical industry
    • Y02P30/20—Technologies relating to oil refining and petrochemical industry using bio-feedstock

Definitions

  • the invention concerns a process for upgrading heavy hydrocarbonaceous feedstocks, and particularly the catalysts feeding of the reactors used in the process.
  • a first object of the invention concerns a process for upgrading heavy hydrocarbonaceous feedstocks in at least one hydroconversion reactor for hydroconversion of said heavy hydrocarbonaceous feedstocks and in at least one hydrotreatment reactor for hydrotreatment of said heavy hydrocarbonaceous feedstocks, said process comprising the preparation of two or more catalysts, each catalyst being prepared from one or more catalyst precursor in at least one specific preparation reactor, said catalyst precursor containing at least one transition metal selected from group IIA, IIIB, IVB, VB, VIB, VIIB, VIII, IB or IIB of the periodic table of elements, and each preparation reactor feeding one or more hydroconversion or hydrotreatment reactor, each catalyst contained in preparation reactors being dedicated to hydroconversion or hydrotreatment of said feedstocks.
  • Such a process permits to obtain, under continuous operating conditions, products of better quality.
  • Preparation reactors dedicated to catalytic precursor activation allow more flexibility.
  • continuous feed to a reactor of the reaction section can be achieved and, what is more, the catalyst preparation reactors can feed different catalytic systems to the hydroconversion reactor and to the hydrotreatment reactor.
  • hydroconversion is meant the breakage of bonds in the molecules of hydrocarbons under hydrogen atmosphere in order to decrease or suppress coke and gas (C1-C4) formation.
  • the breakage of bonds itself is mainly driven by temperature, the catalyst being used to promote hydrogen incorporation into the products.
  • hydroconversion is used to differentiate from “hydrocracking” where the breakage of bonds is promoted by the catalyst.
  • Catalysts for hydroconversion processes are based on metals from Group IIA, IIIB, IVB, VB, VIB, VIIB, VIII, IB and IIB.
  • hydrotreatment is meant the removal of contaminants like sulfur, nitrogen, oxygen, metals, CCR (Conradson Carbon Residue), . . . , from a hydrocarbon stream under hydrogen atmosphere.
  • Catalysts for hydrotreatment are the same as for hydroconversion, however with a preference, thanks to their higher activity, for metals of groups VB and VIB promoted or not with metals from group VIII.
  • Hydroconversion will preferably be performed before hydrotreatment, although hydrotreatment may precede hydroconversion.
  • each preparation reactor may be fed with a part of the feedstock to treat.
  • a liquid hydrocarbon may be fed to the preparation reactor for obtaining a less viscous mixture, in addition to the feedstock to treat or in replacement of this feedstock.
  • Preparation reactors may also be fed with a sulfiding agent for activating the catalyst precursor.
  • Sulfiding agent may be for example DMSO (dimethylsulfoxide), DMDS (dimethyldisulfide), elemental sulfur or H 2 S, pure or in mixtures coming from refinery sources, or any appropriate sulfur containing compound.
  • DMSO dimethylsulfoxide
  • DMDS dimethyldisulfide
  • elemental sulfur or H 2 S pure or in mixtures coming from refinery sources, or any appropriate sulfur containing compound.
  • sulfidation of the catalyst precursor is then performed by the sulfur contained in the feedstock.
  • Catalytic precursor activation conversion of precursor to active sulfur specie of the metal contained in the precursor may be achieved in dedicated vessels.
  • the mixture is heated under programmable operating conditions (temperature, pressure, concentration of sulfidation agent, residence time).
  • crushed solids or other additives can be added (example crushed coke, 2% wt, granulometry 300 to 500 microns; alumina; thiosilicates; sulfonates of calcium carbonate; as well as any other suitable additive as those described in U.S. Pat. No. 5,594,945).
  • Hydrogen may also be added to preparation reactors. Such addition helps to control activity of the very active sulfur specie of the activated catalyst such that coking of the catalyst is reduced or avoided.
  • each dedicated catalyst is prepared in at least two preparation reactors.
  • the hydroconversion reactors or the hydrotreatment reactor can then be continuously fed with the catalyst.
  • Reaction temperature for hydroconversion may range from 360° C. to 480° C., preferably from 400 to 440° C., under a pressure of 50 to 300 bars, preferably from 100 to 200 bars.
  • Reaction temperature for hydrotreatment may range from 360° C. to 480° C., preferably from 380 to 440° C., under a pressure of 50 to 300 bars, preferably from 100 to 200 bars.
  • Hydrotreatment and hydroconversion reactors can operate in upflow or downflow reactor. These reactors are preferably perfectly stirred reactors (CTSR).
  • CSR perfectly stirred reactors
  • Each reactor is fed with at least one slurry issued from a catalyst preparation reactor.
  • the slurry consisting of feedstock containing activated catalyst, hydrogen and possibly other additives, and additional hydrogen if needed, is pressurized and enters the hydroconversion reactor and the hydrotreatment reactor.
  • the slurry is preheated before pressurization.
  • catalyst(s) dedicated to hydroconversion contain one transition metal selected from group VB, VIB, VIII, in an active state
  • catalyst(s) dedicated to Hydrotreatment contain two transition metals in an active state, one transition metal being selected from group VB, VIB, VIII and another transition metal being selected from group VIII.
  • Metals active for hydroconversion are preferably: Mo, Ni, Co, W, Cr, V, Fe.
  • Catalyst(s) dedicated to hydroconversion may contain V, Mo or Fe and catalyst(s) dedicated to hydrotreatment may contain the following combination: Mo—Ni, or Mo—V, or Fe—Ni.
  • catalyst(s) dedicated to hydroconversion contain from 20 ppm to 700 ppm of transition metal (weight ratio of transition metal to the feedstock), preferably from 250 to 650 ppm, most preferably from 300 to 600 ppm.
  • the whole content of transition metals in catalyst(s) dedicated to hydrotreatment ranges from 200 to 1000 ppm (weight ratio of transition metal to the feedstock), preferably from 250 to 900 ppm, most preferably from 300 to 500 ppm.
  • Catalysts precursors may be selected from naphtenates, octoates, and oxides.
  • precursors containing Mo will be naphtenates
  • precursors containing Ni will be octoate, such as 2-ethyl hexanoate
  • precursors containing V will be acetylacetonate or acetoacetonate.
  • catalysts precursor of monometallic catalysts may also be an organometallic coordination compound of formula C 1 C 2 ML n (I), where
  • a fused ring is a ring having two carbon atoms and one bond in common with another ring.
  • each of C 1 or C 2 is a C 5 -C 8 monocyclic polyene ligand comprising from 0 to 5 substituents R, each substituent R being the same of different, R being defined as above.
  • Polyenes are poly-unsaturated organic compounds that contain one or more sequences of alternating double and single carbon-carbon bonds.
  • each of C 1 or C 2 may be substituted or unsubstituted cyclopentadiene.
  • the substituents may be the same as substituents R described above.
  • the organometallic coordination compound is a metallocene compound presenting the general formula (II) below
  • R substituted or unsubstituted cyclopentadienyl ligands are pi-bonded to M, and L ligands are sigma-bonded to M, and where M, L, R and n are defined as in formula (I).
  • metallocene compounds consist of two cyclopentadienyl anions (substituted or not) bound to a metal center in a “sandwich” structure.
  • M is selected from Group IIA, IIB, IIIB, IVB, VB, VIB, VIIB or VIII of the periodic table of the elements, preferably M is selected from Fe, V or Mo.
  • the ligand -L is selected from:
  • the catalytic precursor is added under different concentration, depending on the type (octoate, naphtenate, metallocene, oxide . . . ) and under several forms: water soluble, oil soluble or finely powdered solid.
  • the oil-soluble metal precursors are available either as pure solids (metallocenes) or as solutions in hydrocarbons.
  • the metal content is known from the atomic weight of the metal and the molecular weight of the precursor molecule.
  • the amount of precursor to add to the feedstock in order to obtain a given metal concentration in the feedstock can thus be calculated.
  • the solutions of oil-soluble precursors in hydrocarbons are analyzed on their metal content.
  • the amount of solution to be added to the feedstock in order to obtain a given metal concentration in the feedstock can thus be calculated.
  • Process according to the invention may be used to upgrade carbonaceous feedstocks comprising an atomic H/C ratio of at least 0.25.
  • feedstocks can be upgraded through this process: atmospheric and vacuum residues, pitch coming from deasphalting, deasphalted oil, visbroken effluents (thermal cracking), shale oils, biomass ex-pyrolysis and ex-hydrothermal treatment, coal and, at least theoretically, petcoke from delayed coker.
  • feedstocks can also be coprocessed together with petroleum residue: tires, polymers, road bitumen.
  • Hydrocarbons are introduced in the column of a gas chromatography column and are separated with the increasing ebullating point. Temperature column is increased. Ebullating points are deducted from a calibrating curve, obtained in the same operating conditions with a known hydrocarbon mixture.
  • As calibration mixture the following may be used:
  • IP Initial Point distillation: temperature corresponding to a curve area of 0.5% of total chromatogram area.
  • FP means Final Point distillation: temperature corresponding to a curve area of 99.5% of total chromatogram area.
  • Shale oil are impurities rich, some impurities being catalysts poisons, such as Arsine (AsH 3 ).
  • Arsine is the worst poison of hydroprocessing catalyst (NiMo, CoMo).
  • Alternative processes for shale oil refining are hampered by the presence of arsine, which poisons their catalytic functions.
  • arsine is deposed on the catalyst and trapped as nickel arsenide.
  • FIG. 1 represents schematically an embodiment of the process according to the invention.
  • FIG. 2 represents H 2 S yields (wt %) for the different tests of example 1 (reaction time: 1 h; temperature: 430° C.).
  • FIG. 3 represents the atomic H/C ratio in liquid in the 500+ fraction for the different tests of example 1 (reaction time: 1 h; temperature: 430° C.).
  • FIG. 4 represents the conversion of the 500 + fraction as a function of the reactor temperature with two oil-soluble iron catalyst precursors: ferrocene (Fe-cene) and iron octoate (Fe-octo).
  • ferrocene Fe-cene
  • Fe-octo iron octoate
  • FIG. 5 represents the conversion of the 500 + fraction as a function of the reactor temperature with two oil-soluble molybdenum catalyst precursors: molybdenocene (Mo-cene) and molybdenum octoate (Mo-octo).
  • Mo-cene molybdenocene
  • Mo-octo molybdenum octoate
  • the represented unit comprises two preparation reactors 10 , 20 for catalyst preparation from catalyst precursor.
  • Each preparation reactor 10 , 20 is dedicated to the preparation of a specific catalyst, intended for hydroconversion (reactor 10 ) or for hydrotreatment (reactor 20 ).
  • Each preparation reactor 10 , 20 is fed with a catalyst precursor 13 , 23 respectively which can be in several forms: water soluble, oil soluble or finely powdered solid.
  • a sulfiding agent 15 , 25 may be added (DMDS, H 2 S, elemental sulfur) as represented on the figure.
  • Hydrogen H 2 12 , 22 may also be added in the preparation reactors 10 , 20 , respectively.
  • Each preparation reactor 10 , 20 may also be fed with the feedstock 11 , 21 to treat.
  • the sulfur contained in the feedstock may be used for activation of the catalyst.
  • a liquid hydrocarbon may be used, for example as solvent, and fed to the preparation reactors 10 , 20 .
  • crushed solids or other additives 14 , 24 can be added (such as crushed coke, 2% wt, granulometry 300 to 500 microns).
  • the unit also comprises a hydroconversion reactor 40 , a hydrotreatment reactor 50 and a separation section 60 .
  • a pre-heater 30 is placed upstream of the hydroconversion reactor 40 for heating the feedstock to treat.
  • a slurry 31 issued from preparation reactor 10 and consisting of the activated hydroconversion catalyst, along with feedstock to treat and/or other hydrocarbonaceous feedstock and eventually other additives, is conducted to the pre-heater 30 .
  • the feedstock to treat may also be fed partly or totally to the pre-heater via line 32 .
  • the heated slurry 41 is then fed to the hydroconversion reactor 40 .
  • Supplementary hydrogen 42 may also be added upstream from reactor 40 .
  • hydrotreatment catalyst 26 prepared in preparation reactor 20 , upstream from hydrotreatment reactor 50 .
  • Hydrogen 52 may also be added, upstream from hydrotreatment reactor 50 .
  • This separation section 60 may for example comprise a flash vessel for gas removing, an atmospheric fractionation and a vacuum fractionation.
  • the vacuum residue is pre-heated to reduce its viscosity and allow its transfer to the reactor.
  • Catalyst precursors molybdenum octoate, nickel octoate, iron octoate, ferrocene and/or molybdenocene
  • liquid DMDS are added to the pre-heated vacuum residue in the reactor which is then closed.
  • Hydrogen is then added and temperature increased with two stages at 250° C. and 320° C. for 10 minutes each. Then the reactor temperature is raised rapidly to the operating value.
  • the reactor is cooled down and depressurized. All gaseous and liquid effluents are collected, weighed and analysed.
  • the gases are analysed on-line by gas chromatography (Agilent G2891 micro Gas Chromatograph) and the reaction products are analysed by high temperature gas chromatography (ASTM D7169) for determining the yields.
  • the total catalytic metal (molar) content is kept constant but the Ni/Mo ratio is varied between 0 and 0.5.
  • the operating temperature is fixed to 430° C. during one hour.
  • Molybdenum octoate has supposedly the following formula: C 32 H 60 MoO 8 .
  • Nickel octoate has the following formula C 16 H 30 NiO 4 .
  • compositions of the products obtained are presented in table 13.
  • Test series have been performed to compare ferrocene and iron octoate as precursors of an active catalytic phase for the hydroconversion of a vacuum residue.
  • Ferrocene has the following formula: Cp 2 Fe (or (C 5 H 5 ) 2 Fe).
  • Iron octoate has the following formula: C 24 H 45 FeO 6
  • 300 mL of feedstock and iron based catalyst precursor are fed into the reactor.
  • 5000 wppm of Fe as Cp 2 Fe or as Fe-octoate is added to the feedstock (wppm: based on the weight of the feedstock).
  • 130 mol % of sulphur (compared to iron) as DMDS is also fed into the reactor as sulphiding agent.
  • the reactor is pressurized with hydrogen and heated to the desired temperature at a heating rate of 5° C./min.
  • This example series shows the potential of metallocenes as precursors for obtaining high hydrogenation activity catalysts for heavy feedstocks hydroconversion.
  • Tests have been performed to compare bis(cyclopentadienyl)molybdenum dichloride and Mo-octoate as precursors of an active catalytic phase for the hydroconversion of a vacuum residue.
  • bis(cyclopentadienyl)molybdenum dichloride has the following formula: Cp 2 MoCl 2 (or (C 5 H 5 ) 2 MoCl 2 ).
  • Molybdenum octoate has supposedly the following formula: C 32 H 60 MoO 8
  • 300 mL of feedstock and molybdenum based catalyst precursor are fed into the reactor.
  • 500 wppm of Mo as Cp 2 MoCl 2 or as Mo-octoate is added to the feedstock (wppm: based on the weight of the feedstock).
  • 260 mol % of sulphur (compared to molybdenum) as DMDS is also fed into the reactor as sulphiding agent.
  • the reactor is pressurized with hydrogen and heated to the desired temperature at a heating rate of 5° C./min.

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JP6685317B2 (ja) * 2014-11-06 2020-04-22 シエル・インターナシヨナル・リサーチ・マートスハツペイ・ベー・ヴエー 高活性および自己活性化特性を有する自己活性型水素化触媒と残油原料を処理するためのその使用
IT201600080528A1 (it) * 2016-08-01 2018-02-01 Luigi Patron Sistema di idroconversione di oli pesanti esente da coking in singolo stadio di reazione con riciclo mediante un reattore a catalizzatore disperso comprendente molibdeno, e relativo metodo di idroconversione
CN111841630A (zh) * 2020-06-24 2020-10-30 中国石油大学(华东) 用于煤/重油加氢共炼的脂肪酸镍油溶性催化剂及其应用
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US10246652B2 (en) 2013-12-23 2019-04-02 Total Marketing Services Process for the dearomatization of petroleum cuts

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